Faux-stone architectural panel system

ABSTRACT

A set of faux-stone architectural panel members can be installed to create a stone-look wall or facade. Each panel member is cast from a concrete mixture of a cement or bonding agent and a light-weight aggregate. The various panel member may have one, two or three courses, i.e., rows, with the courses being offset at their ends, so as to achieve mating tenons and voids in respect to adjacent successive panel members. The tenons and voids of the panel members interfit or dovetail at corners. A coloring agent is applied onto said stone faces of the panel members. Hanger straps are embedded in the panel members and protrude up from them for attaching to a wall substrate using drywall screws or similar fasteners.

This is a continuation-in-part of my co-pending U.S. patent application Ser. No. 11/192,685, filed Jul. 29, 2005, which claims priority of U.S. Provisional Application Ser. No. 60/592,473, filed Jul. 30, 2004.

BACKGROUND OF THE INVENTION

This invention relates to modes of applying decorative stonework or brickwork to interior and exterior walls, and is more particularly concerned with the application of a system of architectural panel elements, i.e., a faux-stone facade, that closely resemble natural stone (or brick, or brick-and-stone) construction.

The practice of covering an interior wall or an exterior wall with stone for aesthetic purposes has traditionally involved standard masonry practices. That is, the stone mason arranges stones onto the wall and sets them in place using a mortar. The mason then fills in the joints between the installed stones with grout, or with additional mortar, to make the wall look as if it were a stone wall. The process of arranging the stones, which are of random shapes and sizes, and adhering the stones to the wall, is tedious and requires substantial skill. The mason has to arrange the stones so as to create uniform gaps between stones. Because of the irregular nature of the shapes and sizes of the stones, the mason spends a significant amount of time piecing the individual stones to achieve an attractive appearance. The stones are affixed to the wall with mortar or with a similar cement material. The process of forming a wall in this fashion is the same whether native stones, cultured stones, or thin bricks (i.e., brick face) are used.

In the standard procedure, a moisture barrier is applied to the vertical substrate (e.g., plywood). Then a wire lath is installed. A scratch coat of Portland cement and sand is mixed together and applied with a trowel onto the wire lath, and the scratch coat is allowed to dry for a few hours. The stone elements (or thin bricks) are laid out in a desired pattern, e.g., in horizontal courses if flat stones or thin bricks are used. The corners of the room or building are cemented in first, from top to bottom, using a mortar to attach to the scratch coat. Then the remainder of the wall is filled in, also using mortar to bond the stones to the scratch coat. After the stone elements have been cemented in place, grout is applied to the joints between stones (or bricks), and the grout is allowed to dry, after which any residual material is brushed or scraped away.

An approach to forming a synthetic decorative brick or stone wall, formed of thin concrete layer using a form having a preset stone or brick design, is described in Stott U.S. Pat. No. 6,355,193. This results in a wall or panel, with a reinforcement, and with a foam layer at the back supporting the thin concrete layer.

OBJECT AND SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide a system of faux-stone (or faux-brick) elements that can be easily installed onto a vertical supporting substrate, which can interfit together without difficulty, and which achieve an attractive appearance that closely simulates a wall formed of native stone.

It is a further object to provide a series of faux-stone wall panel elements that are relatively light in weight, which includes means for attaching to the vertical substrate using common fasteners, such as nails or drywall screws, and which assemble next to one another in a way that creates a natural look without significant gaps.

A still further object is to provide a faux-stone wall system that can be constructed without need for Portland-cement-based mortar to set the elements in place, and for which the installer does not need special training or experience in masonry work.

According to one aspect of this invention, a faux-stone architectural panel element is formed of a concrete mixture, i.e, a combination of a cement material such as Portland cement and a light-weight aggregate material, which may incorporate particles of vermiculite, pearlite, and/or zeolite. The material is poured into a rubber mold, and subjected to vibration or shaking so that the heavier concrete material gravitates to the bottom to form the stone face, and the lighter materials, plus any incorporated air bubbles, rise to the upper part, which becomes the back side of the architectural panel element. The rubber mold can be constructed by first placing one, two, or three courses (i.e., horizontal rows) of stones into a frame. The stones are placed so that the ends of the courses are offset relative to the adjacent courses above and/or below. This effect forms voids and projections or tenons, where the tenon on one panel fits into the void at the same course or level on the next panel, so that the stone faces interlace to create a natural look. When the stones are properly arranged, the rubber material is poured in place into the form and allowed to set and harden, thus forming the mold. The same frame and stones can be used to create a series of identical molds, so that the a number of these concrete faux-stone panel elements can be formed. The material is poured into the mold and allowed to set and cure to form the panel. Also, a metal support strip (or two or more strips) are embedded into the concrete material, with a portion of the strip(s) extending from the top side of the panel. This creates a hanger for fastening the architectural panel element onto the plywood or other wall substrate with drywall screws or other suitable fasteners.

Once a panel has been created in this fashion, the panel itself may be placed into a frame to create another identical form using the rubber material.

In the architectural panel, the front side has a number of stone faces, molded in the shape of the original stones that were used for constructing the form. The stone faces project out in a seemingly irregular and uneven manner, as would the native stones. These stone faces may be given a surface treatment, i.e., colorant, to resemble one or another type of stone or mineral.

A faux-stone architectural panel formed according to an embodiment of this invention is made of a concrete material (cement binder agent blended with a light-weight aggregate material) and is molded so as to have a plurality of stone faces at its front side. These are arranged in at least two horizontal courses extending between left and right ends of the architectural panel. The courses each have an offset at its ends relative to the course or courses adjacent to it, so as to achieve mating tenons and voids in respect to a like architectural panel positioned alongside. Most preferably the tenons and voids are “square,” that is, they have the same horizontal extent as the thickness of the panel, and can interfit or dovetail at corners. Each such panel has at least one metal hanger strap embedded into the panel and protruding upward therefrom at its rear side.

The strap provides means for attaching the panel to the vertical substrate. A stone-look wall or facade is then assembled from a set of these faux-stone architectural panel members, with the faux-stone wall being mounted onto the vertical supporting substrate. Each such architectural panel member is formed of a concrete material made of a cement binder agent blended with a light-weight aggregate material, as described previously, and molded so as to have a plurality of stone faces on its front surface. These forming at least one horizontal course, or row of stone faces. Each faux-stone architectural panel member includes one, two, or three metal hanger straps, depending on the size of the panel element. The straps are embedded into the panel and protrude upward at its rear side. The set includes panel elements made of two courses, some made of three courses, and some of one course. There can be long and short panel elements of each variety. This use of architectural faux-stone elements of different height, i.e., one, two, or three courses in height, allows the panels themselves to be staggered up and down so as to break up any sense of horizontal repetition across the facade.

There are other faux-stone elements provided as well, e.g., sills, individual stone elements, arches, keystone elements, etc., as needed to complete the wall, or to fill in around a door, window, or other penetration.

The shape of the architectural panel provides repeats from one panel to the next for ease of installation, but the variety across the stone faces of the panel keeps the repeat from being obvious, and so the finished wall has a natural stone look.

Of course, as aforementioned, this same technique can be used to create a faux-brick, or faux-block wall as well, if that is desired, and so the terms used here should be interpreted broadly to encompass such possibilities.

The above and many other objects, features, and advantages of this invention will become apparent to persons skilled in the art from the ensuing description of a preferred embodiment, which should be considered in connection with the accompanying Drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a two-course faux stone architectural panel member according to one embodiment of this invention.

FIG. 2 is an a perspective view of an assortment of faux stone panel members of this invention, which are employed together to construct a faux stone wall.

FIG. 3 is a perspective view of a portion of a faux stone wall assembled according to this embodiment.

FIG. 4 illustrates the process of assembling the faux stone wall of this embodiment.

FIG. 5 is a perspective view of a frame and stone assembly used as a master for creating a form or mold in which the panel member is produced.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

With reference to the Drawing, and initially to FIG. 1 thereof, a concrete faux-stone wall panel element 10 is shown here with a front face formed to simulate natural stones. The element 10 is molded of a concrete formed of a mixture of Portland cement and an aggregate made of light-weight material, preferably particles of vermiculite and zeolite, and possibly also pearlite. In some cases, particles of a plastic foam material, i.e., foamed styrene, can be used, as well as standard materials such as sand or other silicate-based material. The molding process will be described in more detail later.

Instead of Portland cement, a synthetic organic polymer may be used as a cement or binding agent, e.g., polyurethane, where appropriate for architectural purposes.

As shown here, the faux-stone panel is formed in two (or more) courses, which have the appearance of layers of stones situated vertically one atop the other. Here there is a first or lower course 12 and a second or upper course 14. In this embodiment the first and second courses 12 and 14 are offset from one another so that there are voids and projections or tenons at the ends, respectively. That is, the two courses 12 and 14 are staggered horizontally. In this panel element 10, the first course 12 has a generally rectangular void 16 at its right end and a corresponding tenon 18 projecting laterally at its left end. The offset of the second course 14 then creates a corresponding tenon 18 at the right end and a void 16 at the left end. The panel element 10 is formed with a generally flat, horizontal surface 20 at the top side of the upper course 14 while the bottom course 12 has a flat, horizontal bottom surface 22. The ends of the courses are generally flat vertical surfaces, with the overhang or tenon 18 having a generally flat horizontal surface as well. Also, the size of the tenons 18 matches that of the voids 16, so that the tenons of a given panel element 10 will fit into the voids at the corresponding course of the next adjacent panel element when they are assembled together.

The thickness of the panel element, i.e., from front to back, is nearly the same as the horizontal extent of the tenons 18 and voids 16, so that adjacent panel elements can interfit one another at corners of the room or space where these are installed.

A front surface 24 of the panel element 10 is formed with a plurality of stone faces 26, 24, which are molded so as to simulate actual stones. This surface 24 is preferably provided with a colorant, which can be applied to the element after it is cast or cured, or can be included in the material when it is molded. The stone faces 26 here are arranged so as to generally follow the courses 12, 14 from left to right, although it is desired that these not follow strict horizontal lines, and some variance occurs between the two ends of the panel member 10.

A metal hanger strap 28 is embedded in the concrete material, and has an end that protrudes up from the back surface of the member 10. Depending upon the length of the element, there can be one, two, or three of these straps in any given panel member. These straps 28 serve as an attachment means for supporting the panel element on the vertical wall substrate. Here, the strap 28 is provided with holes for accepting threaded fasteners such as a drywall screws.

In practice, an assortment of sizes of these faux-stone panel elements would be employed in constructing FIG. 2 shows an array of the panel elements that would typically be employed. At the left is a short two-course panel element 10, as described already, and next to that is a long two-course panel panel member 10 a. This element 10 a is approximately twice the horizontal length of the panel member 10, and has two support straps 28. The dimensions of the offsets, i.e., the voids and tenons, is the same as on the panel member 10. Also shown here is a single-course wall element 110, and a double-length single course element 110 a. These are generally the same construction as described before, except that with the single course, there is no offset and no void or tenon. These can be used as “jump” blocks or panels to avoid repetitions of the same panel horizontally, by stepping the height of panels up one course. Also shown in FIG. 3 is a three-course panel 210, here shown as double-width, with a pair of hanger straps 28. It is possible to have four or more courses formed in any given panel element, or to provide these with a width of three times (or more) of the single-width panel 10.

While not shown here, the assortment of elements would typically include accessory pieces, such as sill stones, caps or coping stones, arched elements for windows or other wall penetrations, special end pieces, etc. These would be formed of the same general materials as the faux-stone wall elements, and can be installed using similar techniques, to be discussed shortly.

FIG. 3 shows a faux-stone wall constructed according the this invention, here formed with a series of sill stones 30 serving as a base. These sill stones 30 are or may be formed as flat slabs from the same material as the faux-stone architectural panel elements 10 as described earlier. The assembly of panel elements 10, 210, 10 a, etc., can be arranged as shown, so that the lowest courses of the panel members 210 and 10 a are aligned and located atop the sill stones 30. Here there is a three-course panel member 210 placed adjacent a two-course member 10 a, so that there is another two-course member 10 a placed atop the first member 10 a, so that the lowest course of that member is aligned with the upper course of the top member of the three-course panel 210. This achieves a jump in the position of the panel members at that location, so that there is not an obvious repeat of the panel elements 10 a, 10 a, etc. The single course panel members 110 can also be used for this purpose, as well as to achieve a level top of the panel assembly.

The manner of assembly of the faux-stone wall can be explained with reference to FIG. 4. As shown here, the panel members 10 or 10 a are placed against associated wall substrates WS, which can be available structural panels, e.g., plywood. A layer of a suitable adhesive 40 is applied to the wall substrates WS, to bond to the back surface of the panel members 10. Then, fasteners are screwed in through the straps 28 into the wall substrate WS. In this illustration, one of the faux-stone structural panel members 10 a is being positioned on top of several other members that have been previously installed. Here, the faux-stone is being placed on two walls that meet at a corner, and it can be seen that the ends of the successive panel members interleave with one another. The position of the void 16 matches the position of the tenon 18 of the adjacent panel member 10 at the corner. The tenon 18 of the panel member that is being positioned then fits across the top of the tenon of the other, previously installed panel member. This helps achieve a natural stone look at the corners, avoids the need for mitering or coping of the panel members at corners.

After the panel members are all installed, grout is applied in a usual fashion at the joints between the panel member.

A stone and frame original or master 50 is shown in FIG. 5, and illustrates the manner of forming the rubber molds that are used in forming the faux stone panels. Here, there is a frame 52 formed of a number of wooden boards, with stacks 54 of boards at the positions that represent the voids 16 in the finished panel members. A number of stones 56 are positioned in place within the frame 52 and may be cemented or bonded with mortar or another agent. Then when the mortar is sufficiently set, a rubber molding compound is poured to cover the top face of the stones 56 as well as the spaces between the stones and the frame. After a sufficient time for the rubber material to set and cure, the finished rubber mold is pulled off and removed from the master 50. This can be repeated any number of times to create additional similar molds. The concrete mixture as discussed previously can be poured into the rubber molds to form the faux stone architectural panel members. The rubber mold is supported in a mold frame, and can be subjected to vibration or shaking to cause the heavier components of the mixture to settle to the bottom (which becomes the front or stone face) and allow the lighter components and any air bubbles to rise towards the top of the mold, i.e., towards the back side of the panel. Of course, the strap(s) 28 are to be inserted into the mixture in the mold before the mixture hardens. This should set and cure for a full day, and then can be removed from the mold.

Once the molded faux-stone panel member 10 is completed, the same may be used as an original or master to create a second rubber mold with the same stone pattern.

As mentioned before, the architectural panel members according to this invention are not limited to the type of stone arrangement of the illustrated embodiment. The panels may include rounded or irregular stone shapes, or may include shapes of bricks, blocks, shells, or other materials as desired, and can be easily created using the same technique and installed in a similar fashion.

While the invention has been described in reference to a preferred embodiment, it should be understood that the invention is not limited to that precise embodiment. Rather, many modifications and variations will present themselves to those skilled in the art without departing from the scope and spirit of the invention, as defined in the appended claims. 

1. A faux-stone architectural panel formed of a concrete material made of a cement binder agent blended with a light-weight aggregate material, and molded so as to have a plurality of stone faces thereon forming at least two horizontal courses extending between left and right ends of the panel; the courses each having an offset at its ends relative to the course or courses adjacent thereto, so as to achieve mating tenons and voids in respect to a like architectural panel positioned alongside; and at least one metal hanger strap embedded into the panel and protruding upward therefrom at a rear side thereof for attaching the panel to a supporting vertical substrate.
 2. A faux-stone architectural panel according to claim 1, comprising a colorant agent applied onto said stone faces.
 3. A faux-stone architectural panel according to claim 1, wherein each the panel is formed of at least three courses.
 4. A faux-stone architectural panel according to claim 3, wherein said cement binder agent includes a Portland cement.
 5. A faux-stone architectural panel according to claim 1, wherein said light-weight aggregate material includes one or more materials of the group consisting of pearlite, zeolite, and vermiculite.
 6. A faux-stone architectural panel according to claim 1, wherein said light-weight aggregate material includes particles of a plastic foam material.
 7. A faux-stone architectural panel according to claim 1, wherein said offsets have a horizontal extent that is substantially equal to the thickness of the panel at the end thereof.
 8. A set of faux-stone architectural panel members which are assembled together to form a faux-stone wall mounted onto a vertical supporting substrate; each said architectural panel member being formed of a concrete material made of a cement binder agent blended with a light-weight aggregate material, and molded so as to have a plurality of stone faces thereon forming at least one horizontal course, and each said faux-stone architectural panel member including at least one metal hanger strap embedded into the panel and protruding upward at a rear side thereof for attacking to said vertical supporting substrate.
 9. A set of faux-stone architectural panel members according to claim 8, comprising at least one panel member formed as a single horizontal course, and at least one panel member formed of two or more horizontal courses, the courses thereof each having an offset at its ends relative to the course or courses thereof adjacent thereto, so as to achieve mating tenons and voids in respect to another successive one of said architectural panel members positioned immediately alongside.
 10. A set of faux-stone architectural panel members according to claim 9, comprising at least one panel member formed of three or more courses.
 11. A set of faux-stone architectural panel members according to claim 9, wherein said offsets have a horizontal extent that is substantially equal to the thickness of the panel member at the end thereof.
 12. A set of faux-stone architectural panel members according to claim 8, comprising a coloring agent applied onto said stone faces. 